FEATURE HVAC
INDUSTRIAL HEATING: is it best to upgrade or replace?
Before deciding whether to replace or upgrade an industrial boiler it is important to carry out a detailed site survey, says Rob Brown from Bosch Commercial & Industrial Heating
can be better sized and located closer to the point of use with appropriate controls to maximise efficiency.
TAKING CONTROL When it comes to controlling modern systems boilers can be turned both on and off remotely through a building management system (BMS) which in turn has significant cost saving benefits, particularly when it comes to labour. With a BMS that allows the remote control of the boiler system there is no need for someone to be on site during the night or the early hours of the morning in order to fire it up before a day’s use. Furthermore, it is possible for the boiler
G
iven the life expectancy of an industrial boiler it can be difficult to
justify investment in modernising or even replacing entire systems during their life cycle to enhance energy efficiency. Investment in an industrial boiler plant
will never be one that can be made without an in-depth analysis of performance and payback period. While a typical system can often be relied upon to stand the test of time over the course of multiple decades, advancements in technology mean it is often pertinent to consider upgrading or replacing systems before the end of their natural life in order to maximise efficiency. With any energy system there is no
such thing as ‘one solution fits all’. It is important to remember that the system in place today may not just require a like- for-like swap and it is vitally important to consider wider implications. Have the site’s requirements changed since the original system was installed? Are there modern technologies on the market that may prove to be a better solution than what was available at the time? Answers to both questions could prove fundamental to the future of the plant. Taking a low temperature system as an example, it may be that a combined heat & power (CHP) module can be installed which essentially gives a boiler plant free heat alongside electricity generation. It could be that the site doesn’t have many hand wash basins which lends itself to
20 MAY 2015 | FACTORY EQUIPMENT
the installation of direct water heaters. Regardless of the circumstances, it’s important to look at the full plant requirements and whether or not the site has the potential for a packaged boiler house. For example, it may lend itself to small de-centralisation and or point of use steam generation which can be achieved with a containerised solution.
A PRE-PACKAGED SOLUTION In the event a site does require a new boiler investing in one housed in a container often proves the favoured option because a new building is unable to be constructed to accommodate it. The convenience of this solution is that a boiler can be delivered and installed in an appropriate location on site for point of use, close to the process application requiring the heat or steam output. It may be that there is only one boiler
on site and another is needed to cater for additional output following a change of requirements. In the case of a steam boiler it may be that the requirement for a statutory shutdown makes it more practical. The flexibility of a containerised boiler house can prove hugely beneficial. It may be that in an application such as a dye works where the tanks need to be pre-heated in the early part of the day before the process takes place. In this cases it can be common for the boiler on site to have been vastly oversized for its requirements so a containerised solution
When upgrading a heating or hot water system on site it is advantageous to speak to a manufacturer or supplier that can offer a wide range of technologies
to monitor its own performance. When upgrading a heating or hot water system on site it is advantageous to speak to a manufacturer or supplier that can offer a wide range of technologies. The largest cost savings generally follow
a site survey which is unbiased toward a particular technology and its suitability for the job. There will become a point at which the best option may be to combine multiple technologies working together to cater for the entire heating, hot water and process heating requirements. Using a steam boiler alongside a CHP
module, a system would effectively be capable of delivering free steam, domestic heating and hot water and secondary heat – not to mention electricity. Some older factories still tend to generate heat from the central boiler house using steam – hot water calorifiers for radiators and hand wash outlets. When you separate the heating and hot water usage from the process heating requirements it can be more cost- effective to install a smaller, separate system to cater for hand wash basins and other non-process heating requirements. Ultimately, the key to maximising boiler performance – whether for hot water or process heating – is to conduct a thorough site survey and understand the requirements of the people and processes before any decisions are made.
Bosch Commercial & industrial Heating T: 0330 123 3004
www.bosch-industrial.co.uk Enter 314
/ FACTORYEQUIPMENT
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